vialtray: make a tray for vials containing 0402/0603 components (in progress)

This doesn't work yet. In particular, going through "cameo" doesn't seem
the most convenient choice, since "cameo" requires paths to be closed,
which is something the paths we use here aren't. (Conceptually, thet are
closed, but the implementation skips some small segments.)

This commit is just a snapshot before I experiment with changing the
algorithm.

vialtray/README

@@ -0,0 +1,4 @@
+vial tray: small lab vials are an excellent place to store 0402 and 0603
+components. The problem is how to store a large number of vials efficiently
+and in some order. This project is about milling openings for vials into a
+piece of wood.

vialtray/doit

@@ -0,0 +1,28 @@
+#!/bin/sh
+DIR=/home/moko/svn.openmoko.org/developers/werner/cncmap
+RECT=$DIR/rect/rect
+ALIGN=$DIR/align/align
+ZMAP=$DIR/zmap/zmap
+GP2RML=$DIR/gp2rml/gp2rml
+CAMEO=../../../cae-tools/cameo/cameo
+
+GEN=${1:-./pcb.pl}
+
+# manual tool positioning !!
+rdate="0 0 0  150 0 0  0 100 0"
+# lower Z by 0.5 mm relative to highest point (-56.8)
+Z=0
+
+rect=`$RECT $rdata | awk '{$3 = ""; print}'`
+
+# cameo: we inline the tool diameter with the data
+
+$GEN |
+  awk '{ if ($3 != "") $3 += '$Z'; print $0; }' |
+  $CAMEO -d 0 |
+  $ALIGN 0 1 $rect |
+        # angle, reference (lower left corner), rect
+  $GP2RML 20 2 2
+        # clearance, xy speed, z speed
+# since everything is in the same plane, z clearance must be thickness plus
+# real clearance !

vialtray/tray.pl

@@ -0,0 +1,258 @@
+#!/usr/bin/perl
+
+use POSIX;
+
+
+$PI = atan2(1, 1)*4;
+$epsilon = 0.02;
+
+$d = 25.4/8;	# 1/8"
+$r = $d/2;
+
+
+sub orig
+{
+    $x0 = $_[0];
+    $y0 = $_[1];
+}
+
+
+sub mil
+{
+    return $_[0]/1000*25.4;
+}
+
+
+sub cut
+{
+    if (defined $x) {
+	if ($x == $_[0]+$x0 && $y == $_[1]+$y0) {
+	    shift @_;
+	    shift @_;
+	} else {
+	    print "\n";
+	}
+    }
+    while (@_) {
+	$x = shift @_;
+	$y = shift @_;
+	$x += $x0;
+	$y += $y0;
+	print "$x $y $z\n";
+    }
+}
+
+
+sub mm
+{
+	local ($x, $y, @m) = @_;
+
+	return ($x*$m[0]+$y*$m[1], $x*$m[2]+$y*$m[3]);
+}
+
+
+sub a2m
+{
+	local ($a) = $_[0]/180*$PI;
+
+	return (cos($a), sin($a), -sin($a), cos($a));
+}
+
+
+sub yarc
+{
+	local ($x, $y, $dx, $dy0, $dy1, $r, @m) = @_;
+	local ($dy);
+
+	$dx = ($dx > 0 ? 1 : -1)*sqrt($r*$r-$dy0*$dy0+$epsilon);
+	$dy = $dy0;
+
+	while (1) {
+		if ($dy0 < $dy1) {
+			last if $dy >= $dy1-$epsilon;
+		} else {
+			last if $dy <= $dy1+$epsilon;
+		}
+		print $x+$dx, " ", $y+$dy, " ", $z, "\n";
+		($dx, $dy) = &mm($dx, $dy, @m);
+	}
+}
+
+
+sub circ
+{
+	local ($x, $y, $r, $n) = @_;
+	local ($a, $dx, $dy);
+
+	for ($a = 0; $a <= 2*$PI+$epsilon; $a += 2*$PI/$n) {
+		$dx = $r*sin($a);
+		$dy = $r*cos($a);
+		print $x+$dx, " ", $y+$dy, " ", $z, "\n";
+	}
+}
+
+
+#
+# general shape:
+#
+#  <------ 150 ------>
+# +-------------------+
+# |                   | ^
+# | () () () () () () | |
+# | () () () () () () | | 90
+# | () () () () () () | |
+# | () () () () () () | |
+# |                   | v
+# +-------------------+
+#
+
+
+# start depth
+$z0 = -0.5;
+
+# floor depth
+$zf = -15;
+
+# maximum depth step
+$zs = 2;
+
+# distance between columns
+$xs = 24;
+
+# distance between vial centers within columns
+$ys = 20;
+
+# vial diameter
+$vd = 18.6;
+
+# minimum wall thickness
+$mw = 2;
+
+$nc = 6;
+$nr = 4;
+
+
+@m_cw = &a2m(1);
+@m_ccw = &a2m(-1);
+
+# vial hole radius
+$vr = $vd/2;
+
+# circle radii: first, last, increment
+$r0 = $r/2;
+$r1 = $vr-$r*0.75;
+$rs = $r*0.75;
+
+#
+# x offset at which the vial bay stops
+#
+
+$t = $ys/2-$mw/2;
+$xo = sqrt($vr*$vr-$t*$t);
+
+#
+# radius of the arcs connecting vial bays
+#
+$br = $vr*($mw/2)/$t;
+
+# x offset of the center of the arcs connecting vial bays
+#
+#$bx = $xo+sqrt($br*$br-($mw/2)*($mw/2));
+$bx = $xo+$xo*($mw/2)/$vr;
+
+print STDERR "t = $t\n";
+print STDERR "xo = $xo\n";
+print STDERR "br = $br\n";
+print STDERR "bx = $bx\n";
+
+# adjust the z step
+
+$nz = POSIX::ceil(($z0-$zf)/$zs);
+$zs = ($z0-$zf)/$nz;
+
+print STDERR "nz = $nz\n";
+print STDERR "zs = $zs\n";
+
+print STDERR "r0 = $r0\n";
+print STDERR "r1 = $r1\n";
+print STDERR "rs = $rs\n";
+
+
+sub do_col
+{
+	local ($x0) = @_;
+	local ($rw, $end);
+
+	for ($rw = 0; $rw != $nr; $rw++) {
+		if ($rw) {
+			$end = $rw == $nr-1 ? $vr : ($ys-$mw)/2;
+			&yarc($x0-$bx, $y0-$ys/2,
+			    1, -$mw/2, $mw/2, $br, @m_ccw);
+			&yarc($x0, $y0,
+			    -1, -($ys-$mw)/2, $end, $vr, @m_cw);
+		} else {
+			&yarc($x0, $y0,
+			    1, -$vr, ($ys-$mw)/2, $vr, @m_cw);
+		}
+		$y0 += $ys;
+	}
+	for ($rw = 0; $rw != $nr; $rw++) {
+		$y0 -= $ys;
+		if ($rw) {
+			$end = $rw == $nr-1 ? $vr : ($ys-$mw)/2;
+			&yarc($x0+$bx, $y0+$ys/2,
+			    -1, $mw/2, -$mw/2, $br, @m_ccw);
+			&yarc($x0, $y0,
+			    1, ($ys-$mw)/2, -$end, $vr, @m_cw);
+		} else {
+			&yarc($x0, $y0,
+			    1, $vr, -($ys-$mw)/2, $vr, @m_cw);
+		}
+	}
+}
+
+
+sub do_cols
+{
+	local ($c, $x);
+
+	$x = $x0;
+	for ($c = 0; $c != $nc; $c++) {
+		&do_col($x);
+		$x += $xs;
+		print "\n";
+	}
+}
+
+
+sub do_circles
+{
+	local ($c, $rw, $x, $y);
+	local ($rr);
+
+	$x = $x0;
+	for ($c = 0; $c != $nc; $c++) {
+		$y = $y0;
+		for ($rw = 0; $rw != $nr; $rw++) {
+			for ($rr = $r0; $rr <= $r1; $rr += $rs) {
+				&circ($x, $y, $rr, 180);
+			}
+			$y += $ys;
+		}
+		$x += $xs;
+		print "\n";
+	}
+}
+
+
+($x0, $y0) = (5+$ys/2, 5+$ys/2);
+
+$z = $z0;
+for ($i = 0; $i != $nz; $i++) {
+	print "#%%r_tool=", $r, "\n";
+	&do_cols;
+
+	print "#%%r_tool=0\n";
+	&do_circles;
+	$z -= $zs;
+}